TITLE PAGE

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Table of Contents
List of Figures .................................................................................................................................... iii
1 INTRODUCTION ........................................................................................................................... 1
2 THEORY ......................................................................................................................................... 1
a) Auxiliary Power Unit APU .............................................................................................. 1
b) Compressors ..................................................................................................................... 1
c) Turbines ............................................................................................................................ 2
3 IMPORTANT EQUIPMENTS........................................................................................................ 3
a) Screwdriver ...................................................................................................................... 3
b) Torque Wrench ................................................................................................................. 3
c) Safety Gloves and Safety Shoes ....................................................................................... 4
d) Jack, Goggles and Harness ............................................................................................... 5
e) Wrench/Spanner ............................................................................................................... 6
f) Allen Key ............................................................................................................................. 6
g) Ratchet Set........................................................................................................................ 7
4 TASKS PERFORMED IN WORKSHOP ....................................................................................... 8
a) Installation of GP7200-Propulsor Buildup Items ............................................................ 8
b) Installation of Fuel Filter Lever Ratchet .......................................................................... 8
c) Inspection of Hydraulic Hoses on the Engine .................................................................. 8
d) Installation of Hydraulic Pressure Hoses ......................................................................... 8
e) Installation of Hydraulic Suction Hose ............................................................................ 9
f) Inspection of Mount Bolts ................................................................................................... 9
g) Removal and Preparation of Shipment of the APU ......................................................... 9
h) APU Build up ................................................................................................................... 9
i) BSI of High Pressure Compressor Section Rotor ................................................................ 9
j) Cleaning Bracket Cowls ...................................................................................................... 9
k) Inspection of Borescope Plug ......................................................................................... 10
l) Fan Blades Installation ....................................................................................................... 10
m) GE90 Engine Pre induction Health Check ..................................................................... 10
n) Main Fuel Pump Interstage Strainer Assembly Inspection ............................................ 10
o) Inspection of Starter Chip Detector ................................................................................ 10
p) Main Fuel Pump Filter Inspection .................................................................................. 10
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 q) Installation of Inlet Cone ................................................................................................ 11
r) Installation and Removal of Fan Cowl Support Beam ...................................................... 11
s) Removal of Fan Case Brackets and Controllers ................................................................ 11
5 CONCLUSIONS ........................................................................................................................... 11
References ........................................................................................................................................ 12
7 APPENDIX ................................................................................................................................... 13

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List of Figures
Figure 1 APU of Aircraft .................................................................................................................... 1
Figure 2 Compressor of Airplane ....................................................................................................... 2
Figure 3 Turbine Section .................................................................................................................... 2
Figure 4 Flathead Screwdriver ........................................................................................................... 3
Figure 5 Phillips Screwdriver ............................................................................................................. 3
Figure 6 Torque Wrench Set .............................................................................................................. 4
Figure 7 Safety Gloves ....................................................................................................................... 4
Figure 8 Safety Shoes ......................................................................................................................... 5
Figure 9 Tripod Jack ........................................................................................................................... 5
Figure 10 Safety Goggles ................................................................................................................... 5
Figure 11 Safety Harness .................................................................................................................... 6
Figure 12 Wrench Set ......................................................................................................................... 6
Figure 13 Allen Key Set ..................................................................................................................... 6
Figure 14 Ratchet Set ......................................................................................................................... 7

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1 INTRODUCTION
Engines are heart of the airplane that provides necessary thrust to the airplane which allows it to
move. There are many complex parts in the engine which must be properly maintained so that they
can work properly. The fuel lines, small electrical mechanisms that induce spark, etc. are examples
of very small parts of engines but also have a lot of importance. This workshop gives us idea about
the different parts of engine, their working and how they are properly maintained.

2 THEORY
Some of the parts or equipment that are maintained in the engine’s workshop are as follows:

a) Auxiliary Power Unit APU

This part helps in starting the engines of airplane initially. The electric power generated from this
part helps all electrical functions possible with in an airplane. It can be said it is a small engine that
drives the airplane bigger engines. In emergency conditions like engine failure they provide back up
power in form of electricity [1]. This is one of the highly maintained equipment in any workshop.

Figure 1 APU of Aircraft

b) Compressors
Compressors of the airplane provide the engine with compressed and comparatively warn air. The
blades of the compressor are shaped like airfoils so that air would be symmetric thus increasing the
efficiency of the engine. There are many stages of low pressure and high pressure compressor. Even

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if one blade of the compressor gets damaged, it can result in engine failure and thus a huge
catastrophe. These are of many types and have many parts that need proper and regular maintenance.

Figure 2 Compressor of Airplane

c) Turbines
These are located after the burner and also contain airfoil blades which can withstand high
temperatures. These shoot air backwards to the nozzle [2] and have many parts that needs proper
maintenance. There are also many types and stages of turbines just as in case of the compressor.
Turbines are also linked by shaft that moves the compressors and turbine and continue the engine
running.

Figure 3 Turbine Section

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3 IMPORTANT EQUIPMENTS
The maintenance workshop contains several parts and equipment that is necessary for keeping the
airplane worthy of safely flying. Some of these important tools are mentioned here in this report.

a) Screwdriver
Even a layman can understand its purpose which is tightening or loosening screws. There are
numerous numbers of screws in the aircraft which makes a common screwdriver an essential tool. It
should also be noted that the there are many types of screwdrivers but the mostly used types are flat
head and Phillips screwdrivers.

Figure 4 Flathead Screwdriver

Figure 5 Phillips Screwdriver

b) Torque Wrench
This is another important equipment used in aviation industry. The purpose of this tool is to loosen
or tighten nuts, bolts, etc. by applying specific required torque. Many nuts and bolts have their own

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specific torques at which they loosen or tightens, this equipment helps the mechanics to safely work
on these nuts and bolts without damaging it by applying unnecessary force. These come in different
sizes and different torques. It should be noted that the manufacturer always guides in Maintenance
Manual that which kind of torque should be applied to loosen or tighten any nut or bolt.

Figure 6 Torque Wrench Set

c) Safety Gloves and Safety Shoes

Working with tools, screws, and hard metal parts, it is necessary to have protection so that the
mechanics do not get hurt. Other reasons to use these are to keep hands and feet from dirt or
protecting them in case any heavy part suddenly falls or breaks off. Cuts can also be prevented by
using this safety equipment.

Figure 7 Safety Gloves

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 Figure 8 Safety Shoes

d) Jack, Goggles and Harness

Jack is used to lift heavy objects such as cars, airplanes, etc. for maintenance purposes. Goggles are
a safety precaution so that no object can harm the eyes. Harness is used while working at heights to
protect the workers in case they fell off.

Figure 9 Tripod Jack

Figure 10 Safety Goggles

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 Figure 11 Safety Harness

e) Wrench/Spanner
This tool helps in tightening or loosening nuts or bolts by applying torque. They come in different
sizes for different nuts or bolts.

Figure 12 Wrench Set

f) Allen Key
It is an L shaped key which is used for tightening or loosening hexagonal types of heads of
fasteners. It also comes in different sizes.

Figure 13 Allen Key Set

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g) Ratchet Set
This tool is designed in a way that it allows to turn the nuts or bolts without lifting and
repositioning it on the fastener. It can work both ways i.e. clockwise direction and anti-clock wise
direction.

Figure 14 Ratchet Set

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4 TASKS PERFORMED IN WORKSHOP
The tasks performed in aircraft’s live environment maintenance are the following. It should be noted
that wearing safety gloves, shoes and goggles are must before engaging in any type of maintenance
task.

a) Installation of GP7200-Propulsor Buildup Items

Firstly, the air manifold duct is installed. After that the upper high pressure duct is installed. HPV air
sense tube is then connected following the installation of pylon interface duct. It is to be then attached
to ECS rigging tool. Now, the pressure regulating valve is installed. After that the starter stub duct
on the pylon interface duct is connected. The high pressure or low pressure duct is installed after
that, and then the low pressure air duct is also installed. The last step is to install the starter duct. But
the inspection of ECS system is necessary. Important tools that are used in this task are torque
wrench, lubricant oil, spanners, Ratchet set and torque seal. It is to be made sure that all the bolts and
nuts are tightened with exact torque as required so that none of the components malfunction later on.

b) Installation of Fuel Filter Lever Ratchet

The level ratchet is a small part that helps in locking the fuel filter. Allen keys can be used to install
this part on the fuel filter. The maximum torque to tighten this part should not be exceeded as given
in Maintenance Manual. It should be verified that the ratchet lever is in contact with the ring of the
fuel filter.

c) Inspection of Hydraulic Hoses on the Engine

The first step is to get the access to the hydraulic hose and have a visual inspection of this component.
If it looks affected or damaged, it is to be replaced as per mentioned in Maintenance Manual. Other
wise no action is needed and it is good to go. It should be noted that this component must be inspected
for the both upper and lower engine hydraulic pumps.

d) Installation of Hydraulic Pressure Hoses

Hydraulic pressure hoses transfers hydraulic fluid to or between the hydraulic components, so they
have a significant role. Ratchet and torque wrench sets in addition to the crow foot are needed to
tighten the nuts and bolts to install this component.

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e) Installation of Hydraulic Suction Hose
As mentioned in the above paragraph, all the same things are needed to install hydraulic suction
hose.

f) Inspection of Mount Bolts

The mount bolts of engines are visually inspected by checking whether the threading is damaged or
not and if any nut is moving freely, it must be immediately changed. Cleaning of these bolts is also
important so that they can work for a long time.

g) Removal and Preparation of Shipment of the APU

First of all, APU is removed from the build-up stand and is installed on the shipping stand. Then it
should be cleaned to remove all the contaminations plus the removed kit should be inspected
properly. The APU is then wrapped with the shroud cover to protect it from all sorts of elements and
water. It is now finally ready to be shipped. Ratchets and socket are needed to remove the APU unit.

h) APU Build up
In this task, APU generator is installed along with the forward mount fitting, AFT mount yoke and
reducer to the fuel cluster. Then APU is installed on the run and transport cart. Shroud cover is also
wrapped around this equipment to protect it from external variables. A safety precaution in this task
is not to work, stand or work under the suspended load because lifting hardware has a minimum
capacity to lift APU. This precaution is to be taken seriously as this can result in severe injury.
Ratchets and sockets are important tools that are required in this task.

i) BSI of High Pressure Compressor Section Rotor

To complete this task, the blisk airfoils of stage 1 compressor are examined for anything like shape
deformity, presence of cracks, etc. Same procedure is done for the high pressure compressor blades.
As there is less space to examine these parts therefore, borescope is used to give proper inspection
to each blade.

j) Cleaning Bracket Cowls

These parts should be properly cleaned and the best way to clean these is using alcohol so that all
the contaminations are removed. There should be a soft towel and brush to thoroughly clean these
parts.

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k) Inspection of Borescope Plug
The inspection of borescope plug is also necessary. The locking ring should appear clean and the
spring can be compressed easily. The locking ring and head should be easily spined with little force
applied. If any damage is inspected then this part should be replaced with the new one.

l) Fan Blades Installation

First, the antigallant paste is applied into the blade. It is to be ensured that the blades are installed in
correct location along with the fan blade spacers. The important tools used in this task are fan case
work stand, protector cover , compressor and wedge mechanical (LPC fan blade lock), pin, drift fan
blade fairing, pin aligning blade fairing.

m) GE90 Engine Pre induction Health Check

Fuel drain tank is needed for this procedure. The pre induction health check of every engine is
important in the field of maintenance.

n) Main Fuel Pump Interstage Strainer Assembly Inspection

This task is done by inspecting main fuel pump interstage assembly inspection. Fuel Drain tank is
also needed in this task when the fuel pipes are disconnected from the fuel pump. It is to be made
sure that there is no crack formation or any type of leakages as they can result in fatal aircraft
accidents.

o) Inspection of Starter Chip Detector

First the drain plug is released so that the fuel can move to the fuel drain tank. Then the starter chip
detector is inspected for any damage. If anything is damaged then this part is replaced with the new
one.

p) Main Fuel Pump Filter Inspection

The fuel pump is inspected for any damage such as leaks and condition of fuel and electrical
connections. The motor brushes are also inspected and if damaged it can be repaired or replaced with
a new one.

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q) Installation of Inlet Cone
The flanges can be lubricated before installation. After this the inlet cone is installed and all the bolts
are tightened at the required torque. Ratchet set is needed for the tightening of bolts. It should be
noted that the bolts should be tightened in a crisscross pattern.

r) Installation and Removal of Fan Cowl Support Beam

First of all it is to be made sure that anti icing system is cool. Then bolts, nuts and washers are to be
removed which support the beam. As this task is done on a certain height off the ground so harness
and sling is necessary to prevent any injury. After the removal, in the same opposite way, it can be
installed back.

s) Removal of Fan Case Brackets and Controllers

Safety harness and extension is necessary in this type of task. In this task, the pressure sensor and
high pressure/ fan air valve controller is removed. Ratchet and socket help in loosening the nuts
and bolts.

5 CONCLUSIONS
To conclude this report, it must be noted that all the procedure should be followed as it is as explained
in the Maintenance Manual. Human safety is the number one priority so always wear safety gloves,
shoes, goggles and cover all etc. A maintenance worker cannot make his/her own rules because those
can lead to lethal aviation accidents. All the tools must be returned after the completion of the
required tasks. Every task should be sincerely and properly completed because hundreds of lives can
be lost just by one small mistake. Proper and full attention must be given to the task while performing
it and do not take risk at any cost. Rules ae meant to be followed, so do not take anything lightly.

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References

[ Phill Henrey, "https://skybrary.aero/articles/auxiliary-power-unit-apu," 14 November 2015.

1 [Online]. Available: https://skybrary.aero.
]

[ "https://www.grc.nasa.gov/www/k-
2 12/UEET/StudentSite/engines.html#:~:text=Jet%20engines%20move%20the%20airplane,plane
] %20to%20fly%20very%20fast.&text=As%20the%20jets%20of%20gas,of%20blades%20called
%20the%20turbine.," [Online]. Available: https://www.grc.nasa.gov.

[ "https://www.aircraftsystemstech.com/p/fuel-system-inspection-and-maintenance.html,"
3 [Online]. Available: https://www.aircraftsystemstech.com.
]

[ T. Morgan, "https://www.quora.com/What-is-the-use-of-an-APU-in-an-aircraft-and-what-
4 happens-to-an-aircraft-if-the-APU-fails," [Online].
]

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7 APPENDIX

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